Double Tread

ABSTRACT

Embodiments of the invention are used to provide ways of tire tread molding and retreading with a double tread rubber body having a unitary structure that comprises two treads in order to remove the need for buffing an oxide layer typically associated with tread molding and curing. Embodiments of the double tread molding and retreading methods also remove the need for cementing the cured tread to prevent future oxidation buildup. Once the double tread is cured and cooled, it is cut along the centerline with a double tread separation apparatus to expose a soft non-oxidized inner rubber. The cutting is much less energy intensive when compared to buffing with an expendable wire brush. There is no risk of spots of oxidized rubber being missed as is the case with buffing. There is little or no dust created.

FIELD OF THE INVENTION

This invention relates generally to the field of tire manufacturing andrepair and more specifically to tire retreading.

BACKGROUND OF THE INVENTION

Tire retreading is a process by which used tires receive a new tread toextend their service life. Since the useful life span of most tires goesfar beyond that of their tread component, reusing old tire casings forretreading is both cost effective and environmentally friendly.Generally, retreading involves removing the old worn out tread from thetire casing and bonding a new tread onto the cleaned tire by a processof vulcanization.

New tread for precured retreading applications is typically molded as asingle piece with the tread pattern on one side. The opposing side islater prepared to bond to the tire. During the molding and curingprocess a hard, shiny and smooth oxide layer forms on the tread. Toprepare the tread to bond to the tire this layer must be removed. Theremoval of this layer is typically done with buffing of the tread usingseveral stages of expendable wire brushes in an energy intensiveprocess. The tread buffing process is not only energy intensive but alsolabor intensive. Once the oxidation layer is buffed off the precuredtread, the new tread is cemented in order to prevent future oxidation.The cement is then covered with gray polyfilm for ultraviolet lightprotection, and the tread is rolled up and covered with stretch wrap toprotect it from moisture, dirt, and containments. Since tread istypically sold by unit weight, cementing, adding polyfilm, and stretchwrapping the new tread increases its cost.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the invention are used to provide ways of tire treadmolding and retreading with a double tread rubber having a unitary treadbody structure that comprises two treads in order to remove the need forbuffing an oxide layer typically associated with tread molding andcuring. Embodiments of the double tread molding and retreading methodsdescribed herein also remove the need for cementing the cured tread toprevent future oxidation buildup. Among various other advantages, is anincrease in the number of treads produced per press cycle, which resultsin additional cost savings. Once the double tread is cured and cooled,it is cut along the centerline with a double tread separation apparatusto expose the soft non-oxidized inner rubber. The cutting is much lessenergy intensive when compared to buffing with an expendable wire brush.There is no risk of spots of oxidized rubber being missed as is the casewith buffing. There is little or no dust created.

In one aspect of the invention, a double tread separation apparatus fortire retreading is provided comprising (a) a frame, (b) a handlingmechanism connected to the frame and adapted for receiving and orientinga double tread, the double tread comprising (i) a first design sidecomprising an upper surface having a first tread pattern molded in aunitary tread body, and (ii) a second design side comprising a lowersurface having a second tread pattern molded in the unitary tread body,the second tread pattern opposingly oriented with respect to the firsttread pattern across a plane between and parallel to the upper and lowersurfaces, the first and second tread patterns adapted for beingindividually applied to a tire casing, and (c) a mechanism forseparating the double tread into the upper and lower surfaces.

In another aspect of the invention, a method is provided for operating adouble tread separation apparatus for tire retreading, the methodcomprising: (a) feeding a double tread strip into a handling mechanismof the double tread separation apparatus, the double tread stripcomprising (i) a first design side comprising an upper surface having afirst tread pattern molded in a unitary tread body, and (ii) a seconddesign side comprising a lower surface having a second tread patternmolded in the unitary tread body, the second tread pattern opposinglyoriented with respect to the first tread pattern across a plane betweenand parallel to the upper and lower surfaces, the first and second treadpatterns adapted for being individually applied to a tire casing, (b)centering the double tread strip along a centerline via the handlingmechanism, and (c) cutting the double tread strip along the centerlineto separate the upper and lower surfaces.

In yet another aspect of the invention, a double tread mold is providedfor forming a double tread for tire retreading, the double tread moldcomprising (a) an upper mold portion for forming an upper surface of thedouble tread; and (b) a lower mold portion for forming a lower surfaceof the double tread, the double tread comprising (i) a first design sidecomprising the upper surface having a first tread pattern molded in aunitary tread body, and (ii) a second design side comprising the lowersurface having a second tread pattern molded in the unitary tread body,the second tread pattern opposingly oriented with respect to the firsttread pattern across a plane between and parallel to the upper and lowersurfaces, the first and second tread patterns adapted for beingindividually applied to a tire casing.

BRIEF DESCRIPTION OF THE DRAWINGS

While the appended claims set forth the features of the presentinvention with particularity, the invention and its advantages are bestunderstood from the following detailed description taken in conjunctionwith the accompanying drawings, of which:

FIG. 1 is a schematic diagram illustrating a one-piece double tread forretreading tires, accordance with an embodiment of the invention;

FIG. 2 is a schematic diagram illustrating the double tread of FIG. 1that is cut along a centerline to expose a soft non-oxidized innerlayer, in accordance with an embodiment of the invention;

FIGS. 2 a and 2 b are schematic diagrams illustrating a double treadseparation apparatus for separating the double tread of FIG. 1 along itscenterline, in accordance with an embodiment of the invention;

FIG. 3 is a schematic diagram illustrating an open position of a doublemold for molding the tread of FIG. 1, in accordance with an embodimentof the invention;

FIG. 4 is a schematic diagram illustrating a closed position of a doublemold for molding the tread of FIG. 1, in accordance with an embodimentof the invention;

FIG. 5 is a flow chart of a method for manufacturing a double tread ofFIG. 1, in accordance with an embodiment of the invention; and

FIG. 6 is a flow chart of a method for retreading a tire using an uncutunitary double tread body of FIG. 1, in accordance with anotherembodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The following examples further illustrate the invention but, of course,should not be construed as in any way limiting its scope.

Turning to FIG. 1, an embodiment of a double tread rubber strip forretreading tires with precured tread is shown. The tread body 100employs a one-piece, or unitary, mold construction and includes twodesign sides 101, 103 respectively comprising upper and lower surfaces102, 104 with dedicated tread patterns 106, 108 molded thereon.Specifically, the lower tread pattern 108 is opposingly oriented withrespect to the upper tread pattern 106 across a plane a-a′ disposed inbetween and parallel to the upper and lower surfaces 102, 104 anddefining a centerline 110 between them. Preferably, the tread patterns106, 108 on each design side are identical. In an alternativeembodiment, the tread patterns 106, 108 are dissimilar. The double treadunitary mold construction and retreading techniques discussed hereinremove the need for buffing an oxide layer typically associated withmolding and curing of tread rubber, the need to apply a cement layer tothe cured tread to prevent future oxidation, as well as the need toapply a polyfilm for UV protection and stretch wrap to preventcontamination of the buffed surface.

As illustrated in FIG. 2, after the double tread is cured and cooled, itis cut along the centerline 110 with a double tread separation apparatus(described below in FIGS. 2 a-2 b) to expose a soft non-oxidized innerrubber layer 200 between the upper and lower tread surfaces 102, 104 forsubsequent bonding to a tire casing. The process of cutting the doubletread body 100 to separate the two tread design sides 101, 103 andcorresponding tread patterns 106, 108 is significantly less energyintensive compared to traditional buffing of a single tread mold with anexpendable wire brush in order to remove the oxide layer formed afterthe curing process. There is no risk of spots of oxidized rubber beingmissed as is the case with buffing. Additionally, there is little or nodust created.

With reference to FIGS. 2 a-2 b, the double tread separation apparatus202 comprises a double tread splitting mechanism 204, connected to aframe 206, for receiving the double tread body 100 and uniformlyseparating the upper and lower surfaces 102, 104 into two separate treadstrips. In one embodiment, the double tread splitting mechanism 204comprises a splitter member 208 disposed behind a blade 210 and having agradient for guiding the separated upper and lower surfaces of thedouble tread body 100 thereon and away from the double tread separationmachine 202. In an embodiment, the blade 210 is mounted to a band saw212, such as a horizontal band saw. In a further embodiment, thesplitter member 208 is mounted directly to the blade 210. Alternatively,the splitter member 208 is mounted to a feed roller support structure214. The double tread separation apparatus 202 further comprises poweredfeed rollers 216 that accept and guide the double tread body 100 andconvey it toward the blade 210 for separating along the centerline.Preferably, the feed rollers 216 are capable of vertically and/orhorizontally floating their position relative to the blade 210 in orderto center the double tread body 100 along its centerline 110. In oneembodiment, the feed rollers are mechanically floated. In anotherembodiment, the feed rollers are floated using electronic controls.

The double tread body 100 is molded via a double mold 300, asillustrated in FIGS. 3 and 4, showing its open and closed positions,respectively. The double mold 300 comprises an upper mold portion 302and a lower mold portion 304 for contemporaneously molding two treadpatterns 106, 108 onto the respective upper and lower surfaces 102, 104of the tread body 100 via a mold press. Preferably, the number ofplatens in the mold press is reduced, as compared to a single treadmold, to accommodate the upper and lower mold portions 302, 304.

Turning to FIG. 5, an embodiment of a method for manufacturing a doubletread for tire retreading is shown. In step 500, a mold press is setupwith a predetermined number of platens to accommodate the upper andlower mold portions of the double mold 300. The molded unitary doubletread body 100 is then cured and cooled, step 502. Next, if the treadmanufacturer has not yet received an order for the double tread body 100from a tire retreading facility, the tread manufacturer stores thedouble tread 100, steps 504-506. Advantageously, the one-piece unitarymolding of the double tread body 100 allows long-term storage withoutthe need for buffing and cementing by preventing the initial formationof an oxide layer between the upper and lower tread surfaces 102, 104since the soft inner rubber layer 200 between them remains unexposeduntil the double tread is separated. When the tread manufacturerreceives an order for the double tread 100, as well as an indicationthat the retreader is capable of and/or prefers to separate the treadsat its own facility, the tread manufacturer ships uncut double treadbody 100 directly to the retreader, steps 508-510. Since the uncutdouble tread 100 does not require an application of a cement layer tothe interior surface of the tread to prevent oxidation , the applicationof a polyfilm, or the need to stretch wrap, the tread manufacturer isable to reduce its cost per unit (e.g., per pound) of produced tread.

When the retreading facility indicates a preference for receivingpre-cut tread, the tread manufacturer separates the two design sideshaving respective tread patterns of the unitary tread body 100 intoseparate tread strips, such as by using a double tread separationapparatus 202 discussed in connection with FIGS. 2 a-2 b above, step512. To ensure that the double tread body 100 is separated evenly alongthe centerline 110, the tread body 100 is centered along the blade 210by floating the feed rollers 216 of the double tread separationapparatus, step 514. In one embodiment, the feed rollers aremechanically floated. In another embodiment, the feed rollers arefloated using electronic controls. Once the unitary tread body 100 iscentered along the blade 210 of the double tread separation apparatus202, the upper and lower surfaces 102, 104 and corresponding treadpatterns 106, 108 are separated by cutting along the centerline 110,step 516. This exposes the non-oxidized inner layer 200 between theupper and lower surfaces of the tread body 100. Therefore, the pre-cutdouble tread needs to be applied to a tire casing within a predeterminedtime period beyond which oxidation of the inner layer 200 is likely tooccur. Preferably, the pre-cut double tread needs to be applied to atire casing within approximately seventy two (72) hours after cuttingand separating the unitary tread body 100. Hence, in step 518, if thetread order indicates that the retreading facility will apply theseparated treads 106, 108 to a tire casing within the 72 hour timeperiod, the tread manufacturer ships the separated tread to theretreading facility without cementing since oxidation of the exposedinner layer 200 is not likely to occur, step 520. As discussed above,both the tread manufacturer and the retreading facility realize costsavings due to a reduction in the shipping weight of the non-cementedtread and absence of the need to buff any oxidation off the double treadbody 100. In steps 522-524, if the retreading facility is unlikely to beable to use the separated double tread within the predetermined time,the tread manufacturer applies a cement layer to the exposed inner layer200 for each separated tread surface 102, 104 and packages the separatedtread surfaces using a polyfilm material, such as polyethylene, andstretch wrap for shipping, steps 522-524.

Turning to FIG. 6, an embodiment of a method for retreading a tire usingan uncut unitary double tread 100 is shown. Preferably, a dedicatedretreading facility processes the double tread 100, however alternativeembodiments include a retreading plant collocated with a treadmanufacturing facility. In steps 600-604, after receiving the uncutunitary double tread 100 from the tread manufacturer, the retreadingfacility inspects used tire casings and removes old tread by buffing itoff the used tire. Next, in step 606, the retreading facility separatesthe cured double tread mold 100 into two tread surfaces in accordancewith steps 512-516 discussed above in connection with FIG. 5. In steps608-610, if more than a predetermined time period is likely to go byafter tread separation (e.g., the retreading plant will benon-operational longer than 72 hours), the exposed inner layer 200 ateach of the separated upper and lower tread surfaces 106, 108 is treatedwith cement to prevent oxidation buildup and polyfilm material is alsoapplied. Otherwise, in steps 612-616, the retreading facility completesthe retreading process within the predetermined time period aftercutting the tread body 100 by applying a cushion gum bonding layer tothe tire casing, applying the separated upper or lower tread surfacewith a corresponding tread pattern design to the tire casing, andvulcanizing the retreaded tire in a curing chamber, such as by way ofelectric or steam heated curing.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

1. A double tread mold for forming a double tread for tire retreading,the double tread mold comprising: an upper mold portion for forming anupper surface of the double tread; and a lower mold portion for forminga lower surface of the double tread, the double tread comprising (a) afirst design side comprising the upper surface having a first treadpattern molded in a unitary tread body, and (b) a second design sidecomprising the lower surface having a second tread pattern molded in theunitary tread body, the second tread pattern opposingly oriented withrespect to the first tread pattern across a plane between and parallelto the upper and lower surfaces, the first and second tread patternsadapted for being individually applied to a tire casing.
 2. The doubletread mold of claim 1, wherein the first and second tread patterns areformed according to the same pattern.
 3. The double tread mold of claim1, wherein the first and second tread patterns are formed according todifferent patterns.
 4. The double tread mold of claim 1, formed via apress adapted for accommodating the upper and lower mold portions in thepress.